Development of a High-Strength Aluminum Cylinder Block for Diesel Engine Employing a New Production Process 2004-01-1447
A high-strength aluminum cylinder block manufactured using a new production process, ASCT (Advanced Semisolid Casting Technology) has been adopted for the newly developed 2.2L 4-cylinder i-CTDi (Intelligent Common rail Turbo Diesel Injection) diesel engine fitted in the new Accord to be marketed in Europe. In the production process, a semisolid aluminum is used during high-pressure die-casting. In addition, newly developed pressure resistant sand cores are used to mold the closed deck. Heat treatment is conducted to ensure a high level of materials strength.
To respond to the high load on the crankshaft journal, die-cast aluminum lower block with cast iron bearing caps inserts are employed. Adopting the dummy head honing to reduce bore deformation and offset cylinders have enabled the achievement a lightweight and compact cylinder configuration matched to the high combustion pressure of the latest diesel engines, while maintaining a high level of quietness.
Thanks to these counter measurements, a 30% weight reduction in the new cylinder block has been achieved compared to that of the conventional cast iron diesel engines of the same displacement.
Citation: Yamazaki, M., Takai, A., Murakami, O., Kawabata, M. et al., "Development of a High-Strength Aluminum Cylinder Block for Diesel Engine Employing a New Production Process," SAE Technical Paper 2004-01-1447, 2004, https://doi.org/10.4271/2004-01-1447. Download Citation